So, the full post-mortem?
Well, I've been using Wordpress for a number of sites since roughly 2003, and I love the down-to-earth simplicity, and especially how user-friendly its back-end is.
So, for this project, I decided to use Wordpress pretty early on. I knew the site was going to be 90% Pages and only 10% (blog) posts, but I was pretty confident I could make it work.
Template-wise, I didn't base it on any existing theme, this was actually the first time I built a theme completely from scratch.
I more or less know what makes Wordpress tick, the first thing I did was create a home page design in Fireworks (a hugely underrated program, I think). Once approved by the client, I then started building completely static HTML pages.
By then I had received most of the actual site content. I think it's always a good idea to develop using real content instead of 'lorem ipsum' dummy stuff. Things like text length, subtitles, inline links, etc. are hugely important for how a page should be designed.
So, only then did I install Wordpress. I created all the pages, nested them appropriately, created the necessary categories and users. I did all this with the Wordpress default theme.
Then, one by one, I replaced the default pages with my own designs. These were based on my initial static HTML pages, I simply added the Wordpress code where needed.
I only used two plugins . One was a breadcrumb plugin (Yoast Breadcrumbs) which I modified heavily to fit my needs. The code generated by the plugin isn't that flexible, I'm thinking of creating my own more developer-friendly version.
The other plugin I used was the excellent Dagon Design Form Mailer. I think it's the single most useful third-party Wordpress plugin out there. Something like that should be included in the core, with database support.
A lot of stuff, especially the homepage, is hardcoded. The client can do his own text corrections, but creating extra Pages in the top level and making them accessible isn't possible without a significant modification of the template files. That's an obvious trade-off to the visually-rich front-end. But I don't see it causing any problems. Even if I get run over by a bus tomorrow, someone else who knows Wordpress can easily add another set of images and link them to a page.
So, any questions?